Systems and methods for isobutyl alcohol (iba) recovery

ABSTRACT

Methods and systems for creating dynamic performance measures (DPMs) for an IBA manufacturing process. Included is a method for monitoring an Isobutyl Alcohol (IBA) recovery system that includes computing at least one of an amount of IBA recovered from the IBA recovery system and an amount of waste material produced from the IBA recovery system, and displaying at least one of the recovered IBA and the waste material produced based on time. The method also includes computing a cost saved based on a cost of virgin IBA and the amount of IBA recovered. Computing an amount of waste material includes measuring waste material flow, and computing a cost of waste material management based on the measured waste material flow and a cost per unit volume to dispose of waste material. The IBA recovery system can include an evaporation IBA recovery system and/or a distillation IBA recovery system.

CLAIM OF PRIORITY

This application claims priority to U.S. Ser. No. 10/199,832, entitled“Systems and Methods for Isobutyl (IBA) Recovery,”, filed on Jul. 19,2002, and U.S. Ser. No. 60/306,542, entitled “Dynamic PerformanceMeasures of IBA Manufacturing Processes,” filed on Jul. 19, 2001, namingRussell Barr as inventor, the contents of which are herein incorporatedby reference in their entirety.

BACKGROUND

(1) Field

The disclosed methods and systems relate generally to process controlindicators, and more particularly to real-time indicators for improvedperformance process control in a manufacturing process that includesIsobutyl Alcohol (IBA).

(2) Description of Relevant Art

In a process plant, various processes are employed to produce amounts ofa desired product. Traditional methods to measure general performance ofmanufacturing operations of a certain product include counting theamount of product produced over a certain period of time, and from thatamount, calculating a cost per unit product. The cost per unit productis typically based on a standard cost function that is associated withthe operation, often developed at the beginning of a fiscal time period,and utilized throughout that period. The cost per unit product is alsooften reported to manufacturing management to evaluate manufacturingperformance, and often serves as a primary measure of manufacturingperformance.

One disadvantage of measuring manufacturing performance by cost per unitproduct is the equal distribution and allocation of plant costs to eachproduct or product line in the determination of cost per unit product,or alternately and additionally, cost allocation based on an algorithmthat does not assign costs correctly. Often, costs in a manufacturingplant are not directly assignable to a product or product line, andtherefore costs must be allocated based on other factors that usuallyhave more to do with the perceived performance of the manufacturingoperation than the actually occurring manufacturing practices.

Another disadvantage of measuring manufacturing performance by cost perunit product is that a considerable percentage of the costs in amanufacturing plant for calculating the cost per unit product, are notwithin the scope of manufacturing's authority; therefore, theperformance measurement of cost per unit product leads to a “volumebase” manufacturing approach that may not properly satisfy market andcorporate requirements.

Furthermore, determining cost per unit product can be based on theamount of each product or product line produced, and this calculationmay not be sensitive to problems incurred in the producing a specificproduct. For example, if a bad batch of a given product is produced anddiscarded, a standard allocation algorithm may not assign the costsassociated with that batch to the specific product, and the costs areallocated to all products.

Other approaches to measuring manufacturing performance involvenon-cost/non-financial measurements and include measurements of quality,delivery integrity, and customer satisfaction. These approaches aregenerally directed to the discrete manufacturing industry and involvecollecting information and displaying results in a traditional daily,weekly, or monthly report format. Such approaches do not provide timelymeasurements to allow operations personnel to improve the process onwhich the measurements were made.

In manufacturing processes wherein Isobutyl Alcohol (IBA) is used, thecost of procuring and disposing of IBA waste can be a significant costfactor in the production of a product. One industry that utilizes IBA isthe pharmaceutical industry. In a competitive market such aspharmaceutical manufacturing, competition can be extreme, especially inthose commodity markets where pharmaceuticals are off-patent and canhence be manufactured by an FDA-approved manufacturer. These genericdrug manufacturers can operate with a downward price pressure on theirproducts and a critical need to control costs to achieve a reasonableprofit margin.

SUMMARY

The disclosed methods and systems include a method for monitoring anIsobutyl Alcohol (IBA) recovery system that includes computing at leastone of an amount of IBA recovered from the IBA recovery system and anamount of waste material produced from the IBA recovery system, and,displaying at least one of the recovered IBA and the waste materialproduced based on time. The method also includes computing a cost savedbased on a cost of virgin IBA and the amount of IBA recovered. Theamount of waste material can be computed by measuring waste materialflow and computing a cost of waste material management based on themeasured waste material flow and a cost per unit volume to dispose ofwaste material. The method can also include measuring at least one of aflow rate of recovered IBA and a flow rate of waste material.

The disclosed methods and systems can be employed with an IBA recoverysystem that includes an evaporation IBA recovery system, a distillationIBA recovery system, or a combination thereof.

Computing an amount of IBA recovered from the IBA recovery system caninclude determining an amount of IBA recovered per unit volume anddetermining a market cost of IBA per unit volume. The computing can alsoinclude providing a measurement of recovered IBA to a processor modulecoupled to receive the measurement, and, processing the measurement toindicate the amount of IBA recovered. The methods and systems can alsoinclude providing an alarm when the computed value of IBA recoveredsatisfies at least one criterion, and/or an alarm when the computedvalue of waste material produced satisfies at least one criterion.

Computing an amount of waste material produced from the IBA recoverysystem can include providing a measurement of waste material to a signalprocessing module coupled to receive the measurement, and processing themeasurement to indicate the amount of waste material produced.

Some embodiments that utilize evaporation recovery units, for example,can include measuring a cost of steam provided to the IBA recoverysystem, and computing a steam cost per unit of IBA recovered based onthe flow rate of recovered IBA and the measured cost of steam. Theseembodiments can also measure a flow of steam to the IBA recovery system,and compute a measure of IBA recovery system steam cost based on theflow of steam and a cost of steam generation. Additionally andoptionally, in some embodiments, the methods and systems can measureelectrical consumption related to the IBA recovery system, and compute ameasure of IBA recovery system electricity cost based on the measuredelectrical consumption and a cost of electricity.

The systems and methods also include a system for monitoring an IsobutylAlcohol (IBA) manufacturing process that includes an IBA recovery systemincluding at least one of an IBA recovery container and a wastecontainer, at least one sensor to provide measurements related to atleast one of the IBA recovery container contents and the waste containercontents, a processor to process the at least one sensor data andcompute at least one of a value representing a volume of the IBArecovery container contents and a value representing a volume of thewaste container contents, and, a display to display data based on atleast one of the value representing the volume of the IBA recoverycontainer contents and the value representing the volume of the wastecontainer contents. The at least one sensor includes a flow meter,and/or the processor can compute at least one of a volume of IBArecovered per unit time and an amount of waste per unit time. Theprocessor can compute at least one of a cost of IBA recovered per unittime and a cost of waste management per unit time. The display candisplay or otherwise represent at least one of a volume of IBA recoveredper unit time, an amount of waste per unit time, a cost of IBA recoveredper unit time, a cost of waste management per unit time, and athroughput.

Also disclosed is a control system for a process having an IsobutylAlcohol (IBA) recovery system, where the control system includes atleast one sensor to provide signals related to at least one of an amountof IBA recovered from the IBA recovery system and an amount of wasteproduced by the IBA recovery system, a processor to receive and processthe signals to compute at least one value related to the amount of IBArecovered and the amount of waste produced, and, a display to displaydata based on at least one of the value related to the amount of IBArecovered and the value related to the amount of waste produced. Thecontrol system can include a control algorithm related to the IBArecovery system and based on the at least one measurement related to theamount of IBA recovered and the amount of waste produced. The at leastone sensor includes a flow meter.

The methods and systems include a method for controlling a processhaving an Isobutyl Alcohol (IBA) recovery system that includes providingmeasurements related to at least one of an amount of IBA recovered fromthe IBA recovery system and an amount of waste produced by the IBArecovery system, processing the measurements to compute at least onevalue representing the amount of IBA recovered and the amount of wasteproduced, and, displaying data based on at least one of the valuerepresenting the amount of IBA recovered and the value representing theamount of waste produced. The processing includes computing at least onedynamic performance measure based on at least one of the valuerepresenting the amount of IBA recovered and the cost of virgin IBA, andthe amount of waste produced and the cost of waste disposal. Thedisplayed data includes graphically presenting at least one dynamicperformance measure based on at least one of the value representing theamount of IBA recovered and the cost of virgin IBA, and the amount ofwaste produced and the cost of waste disposal. Also provided can be atleast one alarm threshold related to at least one of an amount of IBArecovered and an amount of waste produced, and the at least one alarmcan be displayed.

The systems and methods include a Dynamic Performance Measure (DPM) foran Isobutyl Alcohol (IBA) recovery system, the DPM including a displayhaving at least one of an amount of IBA recovered from the IBA recoverysystem and an amount of waste material produced from the IBA recoverysystem. The DPM includes a means for providing a cost of virgin IBA, ameans for providing a measure of waste material flow and a means forproviding cost per unit volume to dispose of waste material, and/or ameans for providing at least one of a flow rate of recovered IBA and aflow rate of waste material.

Other objects and advantages will become obvious hereinafter in thespecification and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates one Isobutyl Alcohol (IBA) manufacturing process;

FIG. 2 illustrates one IBA recovery system for a IBA manufacturingprocess;

FIG. 3 shows exemplary Dynamic Performance Measures (DPMs) for an IBAmanufacturing process;

FIG. 4 is an example management display that can be generated fromhistorized data of DPMs such as those of FIG. 3; and,

FIG. 5 illustrates one embodiment of an I/A Series system.

DESCRIPTION

To provide an overall understanding, certain illustrative embodimentswill now be described; however, it will be understood by one of ordinaryskill in the art that the systems and methods described herein can beadapted and modified to provide systems and methods for other suitableapplications and that other additions and modifications can be madewithout departing from the scope of the systems and methods describedherein.

Unless otherwise specified, the illustrated embodiments can beunderstood as providing exemplary features of varying detail of certainembodiments, and therefore, unless otherwise specified, features,components, modules, and/or aspects of the illustrations can beotherwise combined, separated, interchanged, and/or rearranged withoutdeparting from the disclosed systems or methods. Additionally, theshapes and sizes of components are also exemplary and unless otherwisespecified, can be altered without affecting the disclosed systems ormethods.

For the described methods and systems, a processor can be understood tobe a processor-controlled device that can include, for example, a PC,workstation, handheld, palm, laptop, cellular telephone, or otherprocessor-controlled device that includes instructions for causing theprocessor to act in accordance with the disclosed methods and systems.References to “a processor” or “the processor” can be understood toinclude one or more processors that can communicate in a stand-aloneand/or a distributed environment(s), and can thus can be configured tocommunicate via wired or wireless communications with other processors,where such one or more processor can be configured to operate on one ormore processor-controlled devices that can be similar or differentdevices. Furthermore, references to memory, unless otherwise specified,can include one or more processor-readable and accessible memoryelements and/or components that can be internal to theprocessor-controlled device, external to the processor-controlleddevice, and can be accessed via a wired or wireless network using avariety of communications protocols, and unless otherwise specified, canbe arranged to include a combination of external and internal memorydevices, where such memory can be contiguous and/or partitioned based onthe application.

The disclosed methods and systems include dynamic performance measures(DPMs) for an Isobutyl Alcohol (IBA) manufacturing process. In anembodiment, IBA recovery and waste material production can be optimizedby aggregating sensor measurements from sensors that produce outputsindicating the amounts of IBA recovered and waste material generated,respectively. The respective sensor measurements can be processed toform a measurement that can be utilized to determine measures in theform of DPMs that relate to the productivity and cost of the IBArecovery and waste management processes. The DPMs can be provided to adisplay that can be viewed by manufacturing or other personnel. Controldecisions can be made to change the IBA recovery and/or waste productionprocesses while the results of such changes can be reflected inreal-time on the DPM displays.

The disclosed systems and methods thus include a real-time (dynamic),sensor-based performance measurement and control. The measurement andcontrol can operate within a manufacturing or process plant havingmultiple processes that form an output product. The processes can beoperated in a pattern to provide manufacturing operations. The controlapparatus can employ multiple sensors coupled to the processes and atleast one processor for providing a real-time indication ofmanufacturing operation performance from sensor signals. Performance canbe indicated in terms of quality of generated products, cost ofproduction, down-time, yield, and/or production.

Sensors can provide signals indicative of a current, present, orexisting state of a respective IBA recovery process. A digitalprocessor, for example, can be coupled to the sensors to receive thesensor signals. One or more processors equipped with a display cansupport the digital processor to determine, from the sensor signals, aquantitative measurement of present performance of the IBA recoveryprocess based on present operation of the IBA recovery process. Forexample, the processor(s) can compute or otherwise calculate productioncost based on sensed present amounts of resources used, and calculatequantity of production based on sensed rate of operation of the IBArecovery process. Accordingly, the display can generally provide agraphical or other representation of economic performance, including forexample, a graph, plot, bar graph, pie chart, or other representation.

The processor can further display data that can indicate presentperformance of the IBA recovery process relative to or based on apredetermined target performance measurement. A control apparatuscoupled to the process can allow operator adjustment to cause states ofthe IBA recovery process to approach operation that provides apredetermined target performance of the manufacturing operations.

The processor(s) or computer can also provide audible and/or visiblealarms based on determined performance measurements. The alarms can becoupled to the digital processor or another processor. For example, theprocessor can provide an alarm when certain criteria are satisfied bythe IBA recovery process and/or by a determined performance. In oneexample, the processor can enable an alarm when a determined performancemeasurement based on present cost of production exceeds a predefinedthreshold, and/or when determined performance measurement based onquality is outside a predefined range.

Accordingly, a measure of present performance of a manufacturing orplant operation, or process unit(s) of a plant or manufacturingoperation, can be computed based on sensor measurements. Process unitscan include, for example, pumps, storage vessels, transfer lines,valves, etc., found in a processing or manufacturing plant. Also,sensors can include temperature sensors, weight sensors, pressuresensors, etc.

In one embodiment, the digital processor can include processor modules,and different sensors can be coupled to the different processor modules.Processor modules can have an object manager to transmit respectivesensor signals to a processor or computer upon request by the processor.Sensor signals can be formed using named series of data points stored ina memory area, and object managers can enable access of data points byname instead of memory location.

The processor can be coupled to an external system for receivingpertinent predefined measurements of target performance. A controlapparatus can be coupled to the digital processor. Additionally, aprocessor member supported by the digital processor can receive workingdata from the computer and store the working data on a common time-linein a global database for general access. The working data can includedetermined performance measurements, predetermined target measurements,indications of sensed states of process means, operator adjustments, andpredefined thresholds for alarms. The database can be a relationaldatabase accessible globally at subsequent times as desired fordifferent applications.

In one embodiment, the disclosed IBA recovery methods and system can beapplied to the production and/or manufacture of pharmaceutical products.The pharmaceutical products can be, for example, Vancomycin. In apharmaceutical manufacturing or production system, sensors can providemeasurements that can be related to the recovery and/or disposal of IBA.In an embodiment, performance measures can be formed to indicate theamount of IBA waste, and relate that waste to waste management costs.Sensors including, for example, flow meters or other measurement devicescan provide input to the performance measures to allow engineering,manufacturing, production, etc., personnel to reduce manufacturing costsas a function of IBA recovery.

Those of ordinary skill in the art will recognize that othermanufacturing processes, including the fertilizer industry, adhesiveindustry, and other industries, can employ IBA and hence IBA recoverysystems and processes. Accordingly, the disclosed methods and systemscan be applied to these and other industries without departing from thescope of the disclosure. Further, the methods and systems can be used inIBA recovery systems that utilize distillation techniques, evaporationtechniques, or combinations thereof.

FIG. 1 shows an illustrative block diagram 10 of a manufacturing processthat uses Isobutyl Alcohol (IBA) to manufacture goods or products.Several major manufacturing industries, including the pharmaceuticalmanufacturing industry, utilize IBA in the manufacturing process,although those with ordinary skill in the art will recognize that themethods and systems herein are not limited to the FIG. 1 system or thepharmaceutical industry.

By-products of a manufacturing process utilizing IBA can be classifiedas hazardous waste and accordingly can require incineration at either anon-site or off-site facility. Although incineration is costly, off-siteincineration can be more expensive than on-site treatment. By recoveringIBA from the by-products, the amount of hazardous waste can be reduced.Additionally, IBA recovery can reduce manufacturing costs by reducingthe need for additional, virgin IBA to be introduced to themanufacturing process. The combination of reduced necessity for new orvirgin IBA and reduced hazardous waste management costs provide anincreased efficiency and cost-effective manufacturing operation.

For a manufacturing system 10 according to FIG. 1, manufacturing inputs12 to the manufacturing process 14 include raw materials, labor,utilities, etc. In a manufacturing process, IBA can be an input to theprocess 14 as a raw material. The illustrated manufacturing process 14produces partially or completely manufactured goods 16 and associatedwith such goods can be by-products. In a manufacturing process, oneby-product can be a spent solvent 18 that can include IBA and hence canbe disposed and treated as a hazardous waste; however, in a system 10according to FIG. 1, the spent solvent 18 can be presented to an IBARecovery Process 20 to recover usable IBA from the spent solvent 18 andreturn the recovered IBA 22 to the manufacturing process 14. One ofordinary skill in the art will recognize that the solvent can beunderstood to be a substance, including a liquid, in which anothersubstance, including another liquid, is dissolved. As indicated herein,by returning recovered IBA 22 to the manufacturing process 14, thedemand and hence cost for virgin IBA decreases, and the net amount ofspent solvent 18 or hazardous waste (i.e., post IBA Recovery 20) alsodecreases to similarly reduce hazardous waste management costs.

FIG. 2 provides an illustrative IBA Recovery Process 20. Per FIG. 2, thespent solvent 18 produced as a by-product from a manufacturing process14 that can include, for example, a manufacturing process according toFIG. 1, is input to an Evaporation Unit 30 with steam 32. Those withordinary skill in the art will recognize that the FIG. 2 IBA RecoveryProcess 20 provides an exemplary evaporation process, however, recoverycan also occur using distillation or other methods, and the methods andsystems herein are not limited to the recovery methodology or process.

In the illustrated system, the spent solvent 18 can be a liquid solutionthat includes water, IBA, and other production-related materials thatcan be stored in, for example, a holding tank. As the solvent 18 istransferred to the Evaporation Unit 30, the volume of the solution inthe Unit 30 can be measured by a sensor 34 that can measure the solutionlevel in the Evaporation Unit 30 and can be configured to provide aninput to control when a heat source within the Evaporation Unit 30 canbe applied to the solution in the Unit 30. Because the boilingtemperature of IBA is greater than the boiling temperature of water, asthe solution in the Unit 30 is heated, initially, material evaporatingfrom the solution includes water and IBA. For a system according to FIG.2, the evaporated material can enter a heat exchanger 36 that can coolthe evaporated material to return the material to a liquid form. At thistime, switch #1 38 is closed and switch #3 48 is open, and hence theliquid from the heat exchanger 36 returns to a tank 40 that also servesas a decanter. Because the density of IBA and water are different, theIBA and water can separate in the decanter tank 40, wherein a pump 42operating in coordination with switch #2 44 can return IBA from the tank40 to the evaporation unit 30, and water (and/or remaining solution) toa waste tank 46. Those with ordinary skill in the art will recognizethat the process of transferring the IBA and water from the tank 40 tothe evaporation unit 30 and waste tank 46 can be performed manually orautomatically without departing from the scope of the disclosed methodsand systems.

Because the separation of the water and IBA from the decanter tank 40 isnot exact, the waste tank contents can include IBA and therefore thewaste tank solution can be treated as hazardous waste; however, becauseof the iterative process of IBA recovery described above and continuedherein, the solution in the waste tank 46 can be a fraction of theamount of solvent 18 entering the evaporation unit 30.

Meanwhile, the temperature in the Evaporation Unit 30 can continue toincrease, where such temperature increases can be controlled manually orautomatically, and can be controlled based on a linear and/or non-linearcontrol As the temperature increases, increasing amounts of waterevaporate and hence more IBA is returned to the Evaporation Unit 30through switch #2 44, until the temperature in the Evaporation Unit 30exceeds the boiling temperature of water. For a system according to FIG.2, once the boiling temperature of water is exceeded in the EvaporationUnit 30, the Evaporation Unit temperature can be rapidly increased,linearly and/or non-linearly, to the boiling temperature of IBA. Acontrol system can be implemented for a system according to FIG. 2 suchthat when the Evaporation Unit temperature approaches the evaporationtemperature of IBA, switch #1 38 can open and switch #3 48 can close tocause the evaporated IBA to pass through the heat exchanger 36, convertto liquid form, and be stored in an IBA recovery tank 50. The IBArecovery tank contents can thereafter be used as an input to amanufacturing process 14, such as, for example, a process according toFIG. 1. Those with ordinary skill in the art will recognize that in someembodiments, the IBA recovery tank contents can be subjected to testingfor quality before being utilized in the manufacturing process.

Those of ordinary skill in the art will recognize that the disclosedmethods and systems can employ various embodiments with multiplevariations. For example, in a continuous IBA recovery system accordingto FIG. 2, a recovery tank 50 may not be employed. This and/or othermodifications can be made as are in the art, without departing from thescope of the disclosed methods and systems.

For an IBA manufacturing process 14 according to FIG. 1 that canimplement an IBA recovery system such as that illustrated in FIG. 2, adynamic performance measure (DPM) can be provided to maximize IBArecovery and steam use, and hence minimize hazardous waste cost andelectricity cost. U.S. Pat. No. 5,134,574, to Beaverstock et al.,entitled “Performance control apparatus and method in a processingplant,” includes further detail on DPMs and is incorporated herein byreference in its entirety. DPMs are metrics that model performancemeasures in process manufacturing operations, wherein the metrics arederived from process instrumentation. DPMs can thus be calculated from aproduction process using real time, preferably object-based process datato display results in real-time to operations, engineering, management,maintenance, and/or appropriate manufacturing or other personnel, asdecision support tools for real-time plant operations. In an embodiment,the DPMs can be presented graphically, and the DPM results can behistorized into a real-time database management system for later use,aggrandizement, and integration with other computer information systemsof the manufacturing plant.

DPMs for a particular plant operation can be based on a businessstrategy for that operation. The DPMs for one process or group thereofin one plant may not be appropriate for the same process of a similarbut different plant. For example, if a manufacturing or process plant isproduction limited, primary measures can include yield or anotherproduction-based statistic; but, if a manufacturing or process plant isnot production limited, primary measures can be resource-based.Developing DPMs therefore includes determining a business strategy, andtranslating that strategy to specific measurements that can assist indetermining whether the strategy is successful, and this success can bemeasured on a process-by-process basis.

Once specific measures are determined, sensor information to make themeasures can be determined. In many manufacturing and process plants,the sensors to make the measures are already installed in themanufacturing or control process. In some cases, new sensors can beinstalled to complete the collection of sensor-based information tomeasure the manufacturing or process operations.

The sensor measurements can be input to a computer or other processingmodule that includes a processor with instructions for causing theprocessor to act in accordance with the disclosed methods and systems.In an embodiment, the sensors can transmit a digital or analog signal tothe processor that is equipped with appropriate input/output capabilityto receive the sensor-based information. The computer can convert, asnecessary, the incoming sensor signals into digital values that can beformed into an input block that includes a collection of records orfields for sensor data. In an embodiment, a particular input block cancorrespond to a particular sensor. An input block can also providegeneral system access to the sensor data by name, where the global nameis based on the name assigned to the input block. This data point or“object” value can be available to any application on the processordevice or computer, or to other processor devices or computers in anetwork to which the processor device or computer is connected, byspecifying the name of any input block or the name of the field orrecord of interest in the input block.

Calculation algorithms or mathematical relationships can also beformulated as part of the DPM construction. The calculation algorithmscan mathematically relate the sensor measurements to a measure of themanufacturing performance. The calculation algorithms can also includetargeted values, predetermined values, and comparisons between presentlycalculated values and the target values.

In an embodiment, an object-oriented programming based block structurecan be established for a computation algorithm. These algorithm blockscan be preprogrammed for DPMs that are frequently encountered, or theycan be programmed for different applications. The sensor-based data canbe input to the algorithm blocks, and this can be accomplished byidentifying in the algorithm block, an input block name and an inputblock parameter (field or record) of interest. The sensor data cantherefore be input to the algorithm block and manipulated according tothe mathematical relationships in the algorithm block.

The algorithm block output can be a global object that may be accessedby the computer or another computer in a network, for example, byspecifying the name of the producing algorithm block. The output objectvalues can be a basis for the DPMs of interest.

In an embodiment, in an algorithm block, the current overall performanceof a manufacturing or plant operation, or process unit(s) of a plant,can be computed based on the sensor measurements. The calculatedperformance can be compared to a targeted performance measure as storedin, for example, an algorithm block or in a historian database. Thecomparison results can be presented to a display object and/or ahistorical database.

Display objects and display templates can be constructed for standardpresentations of the DPMs, and can include line graphs that depict theDPM value over a period of time (historized), an indication of the DPMtarget value, and an indication of pertinent alarm limits. In anembodiment, the x and y axes can be labeled for the application and caninclude a directional indicator showing the direction of increasingperformance. Display objects can be combined with other graphics tobuild an entire display template.

Subsequent to the building and displaying of the comparison results invarious display objects, an operator/user can adjust controls and henceprocesses accordingly. The real-time display of the compared calculatedperformance and target performance in terms of production/resourcefactors of administration, can enable operator adjustment of processes,and hence resource/production factors, immediately during subjectmanufacturing toward target performance, i.e., toward desired values ofresource/production factors. These adjustments can be recorded in ahistorian database. A historical database can therefore include sensedstates of processes, operator adjustments, calculated performancemeasurements, and predefined target measures. Because an operator canreceive real-time feedback of economic performance, adjustments to aprocess can be evaluated based on the adjustments' impact onperformance.

Returning now to an IBA manufacturing and recovery processing system,such as those according to FIGS. 1 and 2, manufacturing strategiesinclude producing an end product at a lowest possible cost. Thesemanufacturing strategies thus include maximizing IBA recovery whileminimizing costs that can be associated with virgin IBA demands,hazardous waste disposal, steam, and electricity. Accordingly, DPMcalculation algorithms or mathematical relationships can be defined asfollows:

Value from Recovered IBA=(IBA flow to the recovery tank)*(cost per unitvolume of virgin IBA)  (1a)

System Throughput=(IBA flow to the recovery tank)  (1b)

As Equation (1a) indicates, the amount of savings from an IBA recoveryprocess 20 such as those according to FIGS. 1 and 2 can be estimated bygenerating a DPM that includes the flow rate of the IBA into a recoverytank such as that provided in FIG. 2 50, and the purchase or marketprice of virgin IBA.

For the illustrated systems of FIGS. 1 and 2, a DPM can also be formedto represent the hazardous waste cost. Because hazardous wastedisposition can be related to a cost per unit volume, a hazardous wasteDPM can be generated according to Equation (2):

Hazardous Waste Cost=(hazardous waste flow)*(disposition cost per unitvolume)  (2)

Additionally, for a system according to FIG. 2 where steam can be aninput to the Evaporation Unit 30, a DPM can represent the cost of steamper unit IBA recovered to the process. In some systems, industrialboilers that can be located throughout a manufacturing plant can producesteam that can be input to a FIG. 2 Evaporation Unit 30. Additionallyand optionally, boilers can generate steam that can be commonly utilizedby different processes and/or manufacturing systems. Steam flow can bemeasured in units of lb/hr (pounds of steam per hour), wherein a DPMrepresenting steam cost can be computed as represented by Equation (3):

IBA Steam Cost=Steam flow*Steam generation cost  (3)

For a system according to FIG. 2, IBA steam cost can be computed perunit time (e.g., hour), while steam flow can be measured in volume orweight (e.g., pounds or liters) per unit time by sensors that caninclude flow meters, orifice plates, etc., although such examples areprovided for illustration and not limitation. Additionally, steamgeneration cost as indicated by Equation (3), can be indicated in costper unit volume or weight, wherein steam generation cost can be relatedto costs of water, fuel costs to heat water that generates steam, etc.

Although Equation (3) includes a DPM representing the IBA steam cost tothe Evaporation Unit, a IBA recovery steam cost can be computed based onthe cost of steam per unit volume or weight of IBA recovered.Accordingly, a DPM can be constructed according to Equation (4):

Steam cost per unit IBA recovered=IBA steam cost/(IBA flow to therecovery tank)  (4)

Those with ordinary skill in the art will recognize that the units forthe parameters in Equation (4) must be harmonized to provide a properDPM. For example, IBA flow to the recovery tank can be measured in unitsof flow rate/hour, while IBA steam cost can be computed in cost/hour.

Additionally, a DPM can be constructed for IBA recovery systems thatrelates to electricity cost and/or usage. For example, Equation (5)represents one electricity cost DPM that can be computed:

Electricity cost per unit IBA recovered=(Electricity cost per hour)*(IBAflow to the Recovery Tank)  (5)

As with all of the DPMs, proper integration of measurements can beutilized to achieve the desired objective. For example, electricalconsumption can be measured in kilowatts, while electricity cost can bemeasured in dollars per kilowatt-hour, to provide a DPM in cost perhour, although such an example is provided for illustration and notlimitation.

Those with ordinary skill in the art will recognize that themeasurements for the DPMs as indicated by Equations (1) through (5) canbe derived according to sensors designed to measure flow rates, forexample, including flow meters that can measure the flows to the wastetank 46 and the IBA recovery tank 50. One flow meter can include acommon orifice plate and differential transmitter combination. Anotheralternative is a vortex flow meter, and those with ordinary skill in theart will recognize that other measurement sensors can provide the flowrate according to the methods and systems herein. According to the DPMs,such flow rates can be measured in real-time.

In an embodiment, for example, an engineer or another viewing the FIG. 3DPMs can determine that the recovered IBA is decreasing while the volumeof waste material is increasing in real-time. Such a determination mayindicate that the temperature of the evaporation unit 30 may not beproperly controlled, which may indicate a problem with either thetemperature sensor or the temperature control unit. Alternately, theoperation of the pump may be at issue. These issues are presented merelyfor illustration and not limitation.

FIG. 3 provides a display of the DPMs for indicating the cost reductionsfor recovered IBA and the costs of hazardous waste disposal as afunction of real-time. An engineer, operator, manufacturing personnel,etc. can view the displays and make manufacturing decisions in real-timeto affect the manufacturing costs. FIG. 4 presents an alternate displaythat can be utilized for reports and can be created from historized datato indicate the effectiveness of the manufacturing strategy.

Those with ordinary skill in the art will recognize that although FIGS.3 and 4 were presented in the illustrated display formats, the methodsand systems herein are neither limited to the information displayed, northe format of the displayed information. Although FIGS. 3 and 4 do notprovide DPM displays for the steam and electricity DPMs of Equations(3), (4), and (5), those with ordinary skill in the art will recognizethat DPM displays similar to those presented in FIGS. 3 and 4 can bepresented for the steam and electricity DPMs of Equations (3), (4), and(5).

FIG. 5 presents an illustrative system 60 that can be implemented in aIBA recovery manufacturing process such as the system of FIGS. 1 and 2,and can further provide for implementation of DPMs as provided herein,and is known as the I/A Series® system from Invensys Systems, Inc. As iswell-known, the I/A Series® system includes I/O Modules 62 such as theFBM44 modules, wherein the I/O Modules 62 can interface to a Fieldbus 63and hence to a Control Processor 64 such as the I/A Series® CP40B. Datafrom sensors 66 can be transferred to the I/O modules 62 using atransmitter, wherein the I/O Modules 62 can convert the sensor data to aformat compatible with the Control Processor 64. In one embodiment ofthe system, the Control Processor 64 can include at least one processorthat includes instructions for causing the processor to implementcontrol algorithms. The Control Processor 64 can further includeinstructions for implementing DPMs such as those provided herein byEquations (1) and (2). As shown for the FIG. 4 system, the ControlProcessor 64 can interface to Workstations 68 through an I/A SeriesNodebus 70 that can be compatible with Ethernet. The Workstations canbe, for example, the I/A Series system AW51E that or another system. TheWorkstations 68 can have access to one or more internal or externaldatabases, and can allow for the display of data such as data based onFIGS. 3 and 4 herein, to allow a processor engineer, manufacturingpersonnel, etc., to monitor and/or affect the controlled systems. Theillustrated Workstations 68 can further interface to another Ethernet 72that provides an interface to, for example, a corporate network that canbe equipped with other Workstations 74, Personal Computers (PCs), etc.,that can also have instructions for causing the display of DPM and/orother information to management or other entities. Historic informationcan also be provided to such systems 74 for local retrieval andanalysis.

Returning to the Control Processor 64 of FIG. 5, depending upon thecontrol algorithms, DPM computations, and any integration therein, theControl Processor 64 can be equipped to transfer control data to, forexample, the valves or sensors 66 via the I/O Modules 62 to achievespecified control objectives. In one embodiment, the control objectivescan be pre-programmed using a multivariable control system such as theConnisseur system provided by Invensys Systems, Inc., however in otherembodiments, manufacturing or other process system adjustments can bemade manually or through the I/A Series Workstations 68.

As indicated earlier, alarms can be utilized to indicate tomanufacturing personnel in real-time that certain, predefined limits arebeing exceeded or otherwise satisfied.

What has thus been described are methods and systems for creatingdynamic performance measures (DPMs) for an IBA manufacturing process. Inan embodiment, IBA recovery and waste material production can beoptimized by aggregating sensor measurements from sensors that produceoutputs indicating the amounts of IBA recovered and waste materialgenerated, respectively. The respective sensor measurements can beprocessed to form a measurement that can be utilized to determinemeasures in the form of DPMs that relate to the productivity and cost ofthe IBA recovery and waste management processes. The DPMs can beprovided to a display that can be viewed by manufacturing or otherpersonnel. Control decisions can be made to change the IBA recoveryand/or waste production processes while the results of such changes canbe reflected in real-time on the DPM displays.

Although the methods and systems have been described relative to aspecific embodiment thereof, they are not so limited. Obviously manymodifications and variations may become apparent in light of the aboveteachings. For example, any sensors providing the necessary sensormeasurements can be used to construct the desired DPMs. The DPMs can bedisplayed using any type of graphical user interface (GUI) that issuitable for presenting information according to the application ofinterest.

The methods and systems described herein are not limited to a particularhardware or software configuration, and may find applicability in manycomputing or processing environments. The methods and systems can beimplemented in hardware or software, or a combination of hardware andsoftware. The methods and systems can be implemented in one or morecomputer programs, where a computer program can be understood to includeone or more processor executable instructions. The computer program(s)can execute on one or more programmable processors, and can be stored onone or more storage medium readable by the processor (including volatileand non-volatile memory and/or storage elements), one or more inputdevices, and/or one or more output devices. The processor thus canaccess one or more input devices to obtain input data, and can accessone or more output devices to communicate output data. The input and/oroutput devices can include one or more of the following: Random AccessMemory (RAM), Redundant Array of Independent Disks (RAID), floppy drive,CD, DVD, magnetic disk, internal hard drive, external hard drive, memorystick, or other storage device capable of being accessed by a processoras provided herein, where such aforementioned examples are notexhaustive, and are for illustration and not limitation.

The computer program(s) is preferably implemented using one or more highlevel procedural or object-oriented programming languages to communicatewith a computer system; however, the program(s) can be implemented inassembly or machine language, if desired. The language can be compiledor interpreted.

The processor(s) can thus be embedded in one or more devices that can beoperated independently or together in a networked environment, where thenetwork can include, for example, a Local Area Network (LAN), wide areanetwork (WAN), and/or can include an intranet and/or the internet and/oranother network. The network(s) can be wired or wireless or acombination thereof and can use one or more communications protocols tofacilitate communications between the different processors. Theprocessors can be configured for distributed processing and can utilize,in some embodiments, a client-server model as needed. Accordingly, themethods and systems can utilize multiple processors and/or processordevices, and the processor instructions can be divided amongst suchsingle or multiple processor/devices.

The device(s) or computer systems that integrate with the processor(s)can include, for example, a personal computer(s), workstation (e.g.,Sun, HP), personal digital assistant (PDA), handheld device such ascellular telephone, or another device capable of being integrated with aprocessor(s) that can operate as provided herein. Accordingly, thedevices provided herein are not exhaustive and are provided forillustration and not limitation.

Many additional changes in the details, materials, and arrangement ofparts, herein described and illustrated, can be made by those skilled inthe art. Accordingly, it will be understood that the following claimsare not to be limited to the embodiments disclosed herein, can includepractices otherwise than specifically described, and are to beinterpreted as broadly as allowed under the law.

1. A monitoring system for control of an Isobutyl Alcohol (IBA) recoverysystem during operation of the recovery system, the monitoring systemcomprising: at least one sensor means for determining at least one of anamount of IBA recovered from the IBA recovery system and an amount ofwaste material produced from the IBA recovery system, during systemoperation; at least one processor, operatively coupled to said at leastone sensor means, adapted to compute at least one of a cost of IBA savedas a result of the amount of IBA recovered during system operation, acost of waste material management as a result of the amount of wastematerial produced from the IBA recovery system during system operation,an IBA recovery system electricity cost for electricity used duringsystem operation, and an IBA recovery system steam cost for steam usedduring system operation, and, at least one output device, operativelycoupled to said at least one processor, adapted to display, for at leastone user, at least one of the said costs, the amount of recovered IBAand the amount of waste material produced based on a measuring timeduring system operation; and at least one input device, adapted toreceive, from said at least one user, input, based upon at least one ofsaid displayed costs and amounts, to make at least one change to atleast one IBA recovery system process.
 2. A system according to claim 1,wherein the at least one a sensor means comprises means for measuringwaste material flow, and wherein the at least one processor is adaptedto compute a cost of waste material management based on the measuredwaste material flow and a cost per unit volume to dispose of wastematerial.
 3. A system according to claim 1, wherein the at least one asensor means comprises means for measuring at least one of a flow rateof recovered IBA and a flow rate of waste material.
 4. A systemaccording to claim 1, wherein the IBA recovery system includes at leastone of an evaporation IBA recovery system and a distillation IBArecovery system.
 5. A system according to claim 1, wherein the sensormeans for determining the amount of IBA recovered comprises sensor meansfor determining an amount of IBA recovered per unit volume.
 6. A systemaccording to claim 1, further comprising a means for determining a costof IBA per unit volume.
 7. A system according to claim 1, furthercomprising a means for providing an alarm when the amount of IBArecovered satisfies at least one criterion.
 8. A system according toclaim 1, further comprising a means for providing an alarm when theamount of waste material produced satisfies at least one criterion.
 9. Asystem for monitoring an Isobutyl Alcohol (IBA) manufacturing processduring operation of the process, comprising, at least one sensor meansfor determining at least one of an IBA recovery container contents and awaste container contents, at least one processor, operatively coupled tosaid at least one sensor means, adapted to process sensor data from theat least one sensor means and to compute at least one of a valuerepresenting a cost of IBA saved as a result of a volume of the IBArecovery container contents, a cost of waste material management as aresult of a volume of the waste container contents, an IBA recoverysystem electricity cost for electricity used during system operation,and an IBA recovery system steam cost for steam used during systemoperation, and, at least one output device, operatively coupled to saidat least one processor, adapted to display, for at least one user, databased on at least one of the said values representing the said costs,the volume of the IBA recovery container contents and the volume of thewaste container contents, to enable process changes for reducing atleast one of the said costs of waste material management, electricity orsteam, or a cost of virgin IBA required as a result of increasing thesaid cost of IBA saved.
 10. A system according to claim 9, wherein theat least one processor is adapted to compute at least one of a volume ofIBA recovered per unit time and an amount of waste material per unittime.
 11. A system according to claim 9, wherein the at least oneprocessor is adapted to compute at least one of a cost of IBA recoveredper unit time and a cost of waste material management per unit time. 12.A system according to claim 9, wherein the at least one output device isadapted to display at least one of a volume of IBA recovered per unittime and an amount of waste material per unit time.
 13. A systemaccording to claim 9, wherein the at least one output device is adaptedto display at least one of a cost of IBA recovered per unit time and acost of waste material management per unit time.
 14. A system accordingto claim 9, wherein the at least one sensor means comprises a flowmeter.
 15. A monitoring system comprising, at least one sensor means forobtaining at least one measurement of at least one of an amount of IBArecovered from an IBA recovery system and an amount of waste materialproduced by the IBA recovery system, at least one processor, operativelycoupled to said at least one sensor means, adapted to receive andprocess the at least one measurement to compute at least one valuerelated to at least one of a cost of IBA saved as a result of the amountof IBA recovered, a cost of waste material management as a result of theamount of waste material produced by the IBA recovery system, an IBArecovery system electricity cost for electricity used during systemoperation, and an IBA recovery system steam cost for steam used duringsystem operation, and, at least one output device, operatively coupledto said at least one processor, adapted to display, for at least oneuser, data based on at least one of the said values related to the saidcosts, the amount of IBA recovered and the amount of waste materialproduced, the data adapted for use to enable process changes forreducing at least one of the said costs of waste material management,electricity or steam, or a cost of virgin IBA required as a result ofincreasing the said cost of IBA saved.
 16. A control system according toclaim 15, wherein the at least one processor is adapted to execute acontrol algorithm related to the IBA recovery system and based on the atleast one measurement related to the amount of IBA recovered and theamount of waste material produced.
 17. A control system according toclaim 15, wherein the at least one sensor means for obtaining at leastone measurement comprises a flow meter.